CAD-driven work instructions operators will actually use

We’ve been seeding work instructions directly from CAD (exploded views, sections, light PMI) for a few disposable assembly lines. Big win: ECOs move faster and visuals reflect the current model. The miss: when I push too much fidelity, operators slow down. Hidden mates imply impossible clearances, default orientations don’t match the bench, and tiny design features read as noise at the station.

What’s working so far: simplified configs with fasteners and cosmetics suppressed, named views aligned to the actual fixture, consistent color-coding for place/press/inspect, and most text callouts added in the WI tool instead of the CAD file. We dry-run each view with two operators before release. Even then, 3D viewers on tablets add lag and revision risk unless PLM and released view sets are locked down.

For those using MBD/PMI or CAD-linked WIs, how do you decide what to omit so the visuals stay clear and fast on the floor? Any lightweight viewers or workflows you trust in regulated environments without drowning operators in detail?